jeres n 100 refractory systems

$: JERES N 100 Refractory Systems$
JERES-N-100 Refractory Systems

Revision 1

Responsibility JER Engineering Division

03 February 2009

Jubail Export Refinery Engineering Standard


JERES-N-100 Rev. 1 Refractory Systems 03 February 2009

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

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Revision Tracking

Revision Revision Date Scope of Revision

1 03 February 2009 Revised to update paragraphs: 7.2.2 and 7.2.3

0 29 April 2008 Issued for bid package.

04 18 April 2008 General revision for consistency with links, incorporated comments from Total specialist.

03 31 March 2008 Issue for Bid Package, only for review

02 23 January 2008 Revision links consistency, refractory limitations

01 03 May 2007 The first official JERES-N-100 is issued.

00 5 February 2007 First draft issued is based on Saudi Aramco SAES-N-100 “Refractory Systems” issue date November 30, 2004. Document was modified to incorporate amendments and modifications.





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Table of Contents

Section Contents Page

1 Scope 4

2 Conflicts, Deviations and Clarifications 4

3 References 5

4 Definitions 7

5 Responsibilities and Documentation 9

6 Design 10

7 Physical Properties 13

8 Metallic Components 13

9 Refractory Systems 15

10 Refractory Installation 15

11 Materials Pre-Shipment Testing 15

12 Claus Unit Special Requirements 16

13 Refractory Material Shipment 18

Appendixes

A Table A – Design Parameters for Castable Refractory Figure 1 – Y Anchor for Dual Layer Gunned Lining 19

B Table 2 – Design Data for Castable Refractory 21

C Table 3 – Mandatory Refractory Systems 22





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1 Scope

1.1 This standard establishes the minimum mandatory requirements for the design and selection of refractory systems for pressure vessels, boilers, process heaters, stacks, breechings, heat exchangers, flare tips, sulfur recovery unit equipment and piping. For Fluid Catalytic Cracking unit vessels and transfer lines application, Contractor shall refer to JERES-N-150.

1.2 Refractory selections shall be limited to material used for erosion resistance and thermal resistance such as castable refractory systems, , and fireclay brick systems. Refractory fiber can only be used when no other technical solution is available; and upon Company written approval. Biosoluble fiber could be used only upon Company approval.

1.3 The requirements detailed in this standard are aimed at standardizing refractory systems used in Jubail Export Refinery facilities.

1.4 For equipment and refractory systems not covered by this standard, the Company Representative shall be contacted for guidance in determining the extent to which this standard is applicable.

1.5 This entire standard may be attached to and made a part of purchase orders.

1.6 This standard covers the design requirements and material selection of refractory system for new and existing equipment.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.





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2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 Company References

Company Engineering Standards

JERES-N-110 Installation Requirements-Castable Refractories

JERES-N-120 Installation Requirements Extreme Erosion Resistant Refractories

JERES-N-130 Installation Requirements-Fireclay Bricks

JERES-N-150 Erosion Resistant Refractory Lining in FCC Piping and Vessels

Company Materials Specification

JERMS-F-3222 Manufacture of Components for Flare Systems

Company Standard Drawings

JERSD-N-0002 Hexsteel Details

JERSD-N-0003 Anchoring Details for Castable Refractories

JERSD-N-0007 Support Details at Nozzles and Manways for Castable Refractories

JERSD-N-0009 Refractory Repairs and Terminations

Commentary Note:





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The Company Drawings listed above and referenced in this standard shall be used as general guide only for the generation of detailed refractory system drawings,specific for each application.

3.2 Industry Codes and Standards

American Society for Testing and Materials

ASTM C20 Standard Test Methods for Apparent Porosity, Water Absorption, Apparent Specific Gravity and Bulk Density of Burned Refractory Brick and Shapes by Boiling Water

ASTM C24 Standard Test Method for Pyrometric Cone Equivalent (PCE) of Fireclay and High Alumina Refractory Materials

ASTM C113 Standard Test Method for Reheat Change of Refractory Brick

ASTM C133 Standard Test Methods for Cold Crushing Strength and Moudulus of Rupture of Refractory Brick and Shapes

ASTM C134 Standard Test Methods for Size, Dimensional Measurement, and Bulk Density of Refractory Brick and Insulating Firebrick

ASTM C182 Standard Test Method for Thermal Conductivity of Insulating Firebrick

ASTM C201 Standard Test Method for Thermal Conductivity of Refrctories

ASTM C704 Standard Test Methods for Abrasion Resistance of Refractory Materials at Room Temperature

ASTM C1113 Standard Test Method for Thermal Conductivity of Refractories by Hot Wire

American Petroleum Institute

API STD 560 Fired Heaters for General Refinery Service

API RP 936 Refractory Installation Quality Control Guidelines-Inspection and Testing Monolithic Refractory Linings and Materials

ISO Standards

ISO 1109 Refractory Products-classification of dense shape





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ISO 10081-1 Basic Refractory Products-Classification Part1: Products Containing Less than 7% Residual Carbon.

ISO 10059-1 Dense, Shaped Refractory Products-Determination of Cold Compressive Strength-Part1: Referee without Packing

ISO 8895 Shaped Insulating Refractory Products-Determination of Cold Crushing strength.

ISO5014 Refractory Products-Determination of Modulus of Rupture at Ambient Temeprature.

ISO5016 Shaped Insulating Refractory Products-Determination of Bulk Density and True Porosity

ISO8894-1 Refractory Matrials-Determination of Thermal Conductivity-Part1: Hot Wire Method.

ISO8894-2 Refractory Materials-Determination of Thermal Conductivity-Part2: hot wire Method.

ISO2477 Shaped Insulating Refractory Products-Determination of Permanent Change in Dimensions on Heating

ISO2478 Dense, Shaped Refractory Products-Determination of Permanent Change in Dimensions on Heating.

4 Definitions

4.1 Definitions presented in the Standard and any other JER document has precedence over other definitions. Conflicts between various definitions shall be resolved by the Company Representative.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

4.2 List of Definitions

Anchors: “V” or “Y” shaped hardware that supports and holds castable refractory in place.





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Air Setting: A curing procedure for refractories that develop a strong bond at air ambient temperatures by virtue of chemical reactions within the binder phase that is usually activated by water additions.

Back-up Layer: In a dual-layer lining, the refractory near the shell.

Casing Temperature: The temperature on the outside surfaces of a fired process heater, including radiant/convection sections, hot flue gas and hot air ducts.

Cold Crushing Strength: A measure of a refractory’s ability to resist failure under a compressive load as determined at room temperature after drying or firing.

Design Engineer: The contracting company that is responsible for specifying refractory system requirements on data sheets or equipment specifications.

Equipment Manufacturer: The company that is responsible for the fabrication of boilers, process heaters, pressure vessels, heat exchangers, and flare tips to which refractory is installed.

Gas bypassing: The ingress of gases between the refractory lining and the shell of equipment.

Gunniting and Gunning: A method of applying castable refractories using pneumatic force.

Hexsteel and “S” bars: Metal supports for extreme erosion-resistant castable refractory.

Hot face: The layer that is exposed to high temperatures and erosion on top of the back-up layer in a dual layer system.

“K” Factor: Thermal conductivity expressed in W/m °C (Btu-in/ft² °F Hr).

“Kcr” Factor: A factor used for correcting the “K” value of a refractory material in air to the “K” value of the material in a hydrogen atmosphere.

Maximum Continuous Use Temperature: The maximum temperature at which a refractory material can be used continuously.

Maximum Service Temperature: The maximum value of the gas temperature or design temperature of a process stream.

Metal Fibers: Stainless steel needles added to refractory castables to increase strength.





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Modulus of Rupture (MOR): A measure of transverse or “cross-breaking” strength of a solid body.

MSDS: Material Safety Data Sheets for refractory material, supplied by the Refractory Manufacturer.

RCF: Stands for Refractory Ceramic Fiber

Plastic Refractory: A pre-mixed, phosphate-bonded refractory material.

Refractory Manufacturer: The company that manufactures refractory products from raw materials.

Refractory Systems: A lining system that is designed to resist high temperatures, hot gases, and the action of erosive materials. Components include anchors, reinforcement, vapor barriers, and refractory materials needed for complete installation.

Jubail Export Refinery Engineer: The Supervisor of the Piping and Valves Unit, Consulting Services Department, Dhahran.

Vapor Barrier: A high-temperature coating that is applied to the shell of equipment to protect the steel from condensing corrosive gases.

Vibration Casting: Castable installation technique where by refractory is mixed with water and placed in a formed enclosure with the aid of vibrator which causes the refractory to become “fluid like” and thereby flow and consolidate to the desired shape of the formed enclosure.

5 Responsibilities and Documentation

5.1 The Design Engineer (Contractor) is responsible for specifying the minimum lining thickness(s) and the refractory systems that are to be used for specific applications, in accordance with this standard.

5.2 The Equipment Manufacturer is responsible for preparing fully detailed engineering drawings of the refractory system and shall submit them to the Company Representative for approval. As a minimum, the drawings shall include anchorage design including spacing and orientation, refractory thicknesses, all materials, surface preparation, and welding details.

5.3 In case RCF use is unavoidable and a written authorization from Company is granted, RCF use will be allowed. In this case, the RCF Manufacturer is responsible





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for the complete design of the RCF system in accordance with the specifications supplied by the Design Engineer (Contractor).

5.4 The Manufacturer shall warrant and provide written documentation, for Company approval, certifying that the supplied product meets the physical properties listed in table 2, Appendix B. For the FCC unit application’s product physical properties to be warranted, refer to a similar table in JERES-N-150.

5.4 The Manufacturer shall provide the restriction on the mixing water composition for each product type. As a minimum the water composition shall be within the limitation presented in paragraph 10.1.9, JERES-N-110.

5.5 For the required documentation from the Installer refer to Installation specifications JERES-N-110, JERES-N-120, JERES-N-130 and JERES-N-150.

6 Design

6.1 General

The use of Refractory Ceramic Fiber (RCF) is forbidden; and it would ONLY be allowed in cases where its use is proved to be unavoidable; such as caulking material for ferrules in waste heat boiler in Claus unit and in spaces between refractory blocks to accommodate thermal expansion. Biosoluble Refractory Ceramic Fiber is allowed and may be used ONLY with prior Company approval.

6.1.1 The design and selection of a refractory system shall be based on the following considerations:

1) The allowable shell metal temperatures.

2) Outside casing temperatures.

3) Maximum service temperatures.

4) Velocities of flue gases or fluids to which the refractory system is exposed.

5) Composition of flue gases and fluids to which the refractory system is exposed.

6) Abrasive particles in the flue gases and fluids to which the refractory system is exposed.

7) Casing or shell pressure and pressure fluctuations.

8) Optimum heat conservation.





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6.1.2 Section 9 of this standard details the minimum design requirements for refractory systems to be specified by the Design Engineer (Contractor).

6.1.3 The Design Engineer (Contractor) shall review and approve the Equipment Manufacturer’s and Refractory Manufacturer’s drawings, as applicable, for compliance with this standard.

6.1.4 Prior to fabrication and production welding, all welding procedures are to be submitted to the Contractor’s Welding Specialist, or a representative designated by the Company.

6.1.5 The continuous-use temperature of hydraulic-setting castable refractory materials shall be a minimum of 95°C above the maximum service temperature of the equipment ‘s hot face layer. For back-up layer, the continuous-use temperature shall be a minimum of 165°C above the calculated temperature of the back-up layer.

6.1.6 The continuous-use temperature of RCF materials shall be a minimum of 150°C above the maximum service temperature of the equipment.

6.1.7 The increase in the value(s) of thermal conductivity of refractory materials in hydrogen rich gases versus the thermal conductivity in air must be considered by the Design Engineer (Contractor). The design “K” values specified in paragraph 7 of this standard are values in air and shall be corrected as required based on the percentage of hydrogen in the process gas.

6.1.8 The minimum thermal coefficient correction factors for increased thermal conductivity due to hydrogen pressures shall be determined as follows:

1) For refractory materials with dry bulk densities up to and including 1280 kg/m3 (80 lb/ft3):

Kcr = (% hydrogen X 0.01) + 1.0.

2) For refractory materials with dry bulk densities above 1280 kg/m³ (80 lb/ft³) up to and including dry bulk densities of 1920 kg/m³ (120 lb/ft³):

Kcr = (% hydrogen X 0.0025) + 1.0.

6.2 Minimum Lining Requirements

6.2.1 Single-Layer Castable Linings

1) This type of lining shall consist of a single layer of a castable refractory to provide thermal insulation and/or erosion resistance.





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2) Unless otherwise specified in this standard the minimum thickness of a single layer of castable refractory supported by anchors shall be 75 mm.

3) The minimum thickness of an erosion-resistant castable refractory supported by hexsteel or “S” bars shall be 25 mm.

6.2.2 Dual Layer Castable Linings

1) This type of refractory lining shall consist of a layer of an insulating back-up refractory covered by a layer of a dense refractory on the hot face.

2) The minimum thicknesses of individual castable layers shall be the thicknesses that are specified in 6.2.1.

6.2.3 Extreme Erosion-Resistant Castable Linings

1) This type of extreme erosion-resistant refractory shall not have an erosion loss that exceeds 6 cm³ after firing at 815°C, in accordance with the procedures specified in ASTM C704.

2) This type of extreme erosion-resistant refractory shall not be used for heat insulation.

3) This type of extreme erosion-resistant refractory shall be supported by means of hexsteel or “S” bars.

4) Fiber reinforcing shall not be used in refractory for hexmetal linings.

6.2.4 Extreme Erosion-Resistant Plastic Castable Linings

This type of extreme erosion-resistant refractory shall have the same erosion resistance characteristic as required for extreme erosion-resistant castable linings.

6.2.5 Void

6.3 Fired Process Heaters

6.3.1 The design temperature of the outside casing surfaces of process fired heaters shall be specified in accordance with API STD 560 and the requirements of this standard.

6.3.2 The casing outside surface design temperature shall be determined in accordance with the criteria below:

The design ambient air temperatures shall be in accordance with JERES-A-112, corresponding to the average annual temperature for the specific site location and still air.





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7 Physical Properties

7.1 General

7.1.1 The use of refractory materials containing asbestos is strictly prohibited.

7.1.2 The Design Engineer shall specify materials with physical properties that are sufficient to meet the design requirements of this standard.

7.1.3 The physical properties for castable refractories shall be in accordance with the Jubail Export Refinery refractory types as specified in 7.2.2.

7.2 Design Data for Castable Refractories

7.2.1 The design parameters to be specified on data sheets and used in design calculations shall, as a minimum, include those listed in Table A, Appendix A, Design Parameters for Castable Refractory. The design values shall be in accordance with values specified in Table 2 Appendix B.,For severe service in FCC unit the design values are found in JERES-N-150.

7.2.2 VOID.

7.2.3 VOID

8 Metallic Components

8.1 General

The material selection for anchorage, supports, and metallic fiber reinforcement shall be based on the design hot-face temperature and corrosion resistance.

8.2 Anchors

8.2.1 Anchors for single-layer, castable linings shall be “V” shaped types. Anchors for the support of dual-layer linings including insulating castable refractory shall be “Y” types.

8.2.2 All “V” and “Y” type anchors shall be specified with rubber or plastic caps.

8.2.3 For details of anchors for castable refractory linings, refer to JERSD-N-0003.





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8.2.4 Individual anchors shall extend a minimum of 75% of the lining thickness. For anchors with unequal leg lengths, the longest leg shall extend a minimum of 75% of the lining thickness.

8.2.5 Void.

8.2.6 Void.

8.3 Hexsteel

8.3.1 Hexsteel shall be the offset-lance, tight-clinched type.

8.3.2 Riveted type hexsteel construction shall only be used on external surfaces of piping that is 12 inch NPS and less.

8.3.3 Hexsteel that is to be supported by “T” studs for two component linings shall be specified as 19 mm, 14 gauge bars.

8.3.4 Hexsteel that is to be welded directly to equipment or piping for the support of 25 mm thick extreme-erosion resistant refractory is to be 25 mm, 14 gauge bars.

8.3.5 All ends of hexsteel are to be welded to edging bars or to adjacent hexsteel. Loose ends are prohibited.

8.3.6 For installation details of hexsteel, refer to JERSD-N-0002.

8.4 Nozzles and Manways

Details of nozzle and manway openings in refractory lined pressure vessels and piping shall be in accordance with JERSD-N-0007.

8.5 Metallic Fiber Reinforcement (Needles)

8.5.1 Unless otherwise specified in this standard, the density of metallic fiber reinforcement shall be 80 kg/m³ (5 lb./ft³).

8.5.2 Metallic fiber reinforcement shall be manufactured from melt extracted material, approximately 0.5 mm in thickness and approximately 25 mm long.

8.6 “S” Bars

“S” bars shall be used only for the support of extreme erosion-resistant refractory where hexsteel is not applicable.





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9 Refractory Systems

9.1 The refractory systems for specific equipment shall be in accordance with the requirements in Table 3, Appendix C, Mandatory Refractory Systems.

9.2 The types of castable refractory material that are specified in Table 3 are the Jubail Export Refinery Refractory Standard Type.

9.3 Complete generic descriptions corresponding to the Jubail Export Refinery refractory type are detailed in the Jubail Export Refinery Materials System (SAMS) catalog.

10 Refractory Installation

10.1 Refractory systems whether shop or field applied shall be installed in accordance with the procedures as detailed in the below listed standards. Vessels and transfer lines in Fluid Catalytic Cracking units shall be in accordance with JERES-N-150.

JERES-N-110 Installation Requirements-Castable Refractories

JERES-N-120 Installation Requirements-Extreme Erosion Resistant Refractories

JERES-N-130 Installation Requirements-Fireclay Bricks

JERES-N-150 Erosion Resistant Refractory Lining in FCC Piping and Vessels

11 Materials Pre-shipment Testing Prior to delivery of refractory materials from the Manufacturer's plant, pre-shipment testing shall be performed as follows:

Refractory purpose Test specimens per sample Sampling Frequency Heat insulating Type 1

3 cubes for compressive strength + density; 1 bar for linear change

1 per batch of 5tons or less

Erosion resistant/heat insulating Type 2

3 cubes for compressive strength + density; 1 bar for linear change; 2 plates for erosion

1 per batch of 2 tones or less.

Extreme duty, erosion resistant Type 3

3 cubes for compressive strength + density; 1 bar for linear change; 2 plates for erosion

1 per batch of 2 tones or less

Samples sizes: Cold crushing cubes 50x50x50mm Permanent Linear Change bars: 230x50x50mm





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Erosion plates 114x114x25mm

All test specimens shall be prepared without metallic fibers.

Certification of pre-shipment test results shall be forwarded to the Company Representative for review prior to any lining application being performed.

Sample test results shall meet the values specified in Table 2, Appendix B. For FCC unit application, refer to JERES-N-150.

If test results for cold crushing fall below the specified value by more than 10%, or if the test result for erosion is more than 10% above the specified value then either re-testing will be required or the relevant batch shall be rejected.

12 Claus unit, special requirements

12.1 General

12.1.1.1 The following requirements prevail on the more general requirements listed in JERES-N-110, JERES-N-120 and JERES-N-130.

12.1.2 The equipments in Claus unit having refractory coating are: Thermal Reactor, Waste heat boiler, converter (reactor), and sulfur storage pit.

12.2 Anchors

V-anchors for single component linings shall be as follows: o Design and layout for single layer linings shall be either straight tine or wave V

anchors;

o For cast and gunned installations, anchor tips shall be 10 minimum to 25 mm maximum from the refractory lining surface;

o For gunned single layer linings behind shrouds, V-anchor tips shall be flush with the specified lining surface to provide for accurate measurement of the applied lining thickness;

o For cast pipe linings, anchors are not required if the lining ID is 26" (660mm) or less, provided that the lining thickness is equal to 75 mm or greater.

o Y or V anchors shall be provided with plastic cap at the extremity to allow thermal expansion without breaking the refractory surface.

Y-anchors for dual-layer linings shall be as per Figure 1, Appendix A. When installed by gunning, the first layer shall be gunned with the stud-welded threaded stud in place, with tape or plastic caps covering the exposed threads. The "V" portion shall then be attached before the second layer is gunned.





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Anchors shall be of the hand-weldable type. Stud gun weldable anchors shall not be used unless approved by Company Representative.

Austenitic stainless steel V and Y-anchors shall be supplied in the fully solution-annealed condition. Solution annealing shall be performed after the anchor is formed.

Metallurgy shall be based on the maximum long-term temperature to which the anchor is exposed at a depth of 25 mm from the lining hot face as per following table.

Maximum Permissible Anchor T° [°C],

25mm from hot face Material (1) (2)

540 Carbon Steel 0.30 wt% Carbon max. 650 12 percent Cr (410S, 405) 870 AISI304, AISI310

1) Metallurgy selection for anchors in high H2S service (i.e., reforming) shall be

approved by the Owner's Engineer. 2) Anchors shall be properly identified using color code per API RP936, appendix C.

12.2.1 Refractory construction specifications

12.2.1.1 Thermal reactor: • A single layer of 230 mm thick, 95 percent alumina firebrick (Babcock and

Wilcox SR90, or equivalent) shall be used for the inner layer of the thermal reactor to protect it during short periods of excessive temperature, and to provide adequate mechanical keying strength between bricks. The Contractor shall also provide an alternative bid with 99 percent alumina firebrick. For temperatures over 1430°C, 99 percent alumina firebrick shall be used.

• Lightweight castable (Harbison-Walker LW No. 28, or equivalent), 115 mm thick (suitable for temperatures up to 1540°C shall be used for the outside refractory layer to provide a better seal with the reactor shell. Type 310 stainless steel V-anchors shall be used to support the castable. Anchor ends shall be located 38mm from the hot inside surface of the castable. V-anchors shall be supplied preferably bent to shape. They shall be annealed after bending. Anchors shall not be bent after welding in place. Anchors shall be 6 mm thick and spaced a maximum of 300 mm apart. Refer to JERES-N-110 for anchor installation requirements.

12.2.1.2 Waste heat-boiler: • The hot inlet tubesheet shall have refractory insulation of high-alumina castable

material (A. P. Green, Greencast 97, or equivalent), either poured or trowelled





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between ferrules. Minimum insulation thickness shall be 100 mm. Anchors shall be 3 mm thick UNS R0556 (Haynes 556 or equivalent) material.

• Tube ferrules shall be furnished at the hot inlet end. They shall be of 85 percent alumina ceramic material. Ferrules shall be wrapped with ceramic fiber (Fibrefax or equivalent) on that portion inserted in the tube.

• Proprietary systems such as hex-head ferrules, two-components hexagon ferrules, etc., may be used for tube sheet lining.

12.2.2 Reactor: • The section at the higher catalyst bed level and below shall be protected with

refractory material. Anchor ends shall be located 38mm from the hot inside surface of the castable. Anchors shall be 6 mm thick and spaced a maximum of 300 mm apart. V-anchors shall be AISI310 or equivalent, supplied preferably bent to shape. They shall be annealed after bending. Anchors shall not be bent after welding in place. The refractory material shall be able to resist temperature of 1540°C, to prevent deformation of the vessel in case of fire.

12.2.3 Sulfur storage pit: • The sulfur storage pit shall be in concrete, having resistance to sulfidation

Portland Cement Grade111A or equivalent. The coverage on reinforcement shall be 60mm minimum.

13 Refractory Material Shipment

All shipments shall have each batch and refractory type clearly identified on the containers.

The water ratio used in qualification testing shall be marked on the refractory containers (except for chemical setting, refractory lining material).

Refractory heat resistant bricks shall be pre-sliced at the design thickness and then packaged in heat-sealed plastic wrap. The qualification testing shall be marked on the containers and included with the installation instructions.





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Appendix A

Table A – Design Parameters for Castable Refractory.

o Cold crushing strength in accordance with ASTM C109 or C133.

o Modulus of Rupture in accordance with ASTM C133 or C583.

o Permanent Linear change (PLC) and return thermal expansion (RTE).

o Erosion loss (not required for insulating castables) in accordance with ASTM C704.

o Thermal conductivity values for the intented service temperature in accordance with ASTM C201 and C417 or C113.

o Bulk density after drying to 110°C.

o Return thermal expansion expressed in millimeters per linear meter (5640-815°C).

o Percentage of water to be used for mixing and installation.

o Volumetric yield (without losses).

o Type of binder, aggregates and maximum grain size.

o Type of packaging for shipment.

o Requirements for storage and expected shelf-life.

o Maximum long-term service temperature (°C).

o Chemical composition (confirm rapid fire Technology RFT fibers are used).





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Figure 1: Y-Anchor for Dual Layer Gunned Linning.





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Appendix B

Table 2 – Design Data for Castable Refractory

Type of Castable Refractory [1][4]

A B C D E F G H I Bulk Density kg/m³

(lb/ft³) Cured and Dried at 815°C

880 (55) [2] 1120 (70) [3]

880 (55) [3] 1280 (80) [3]

2080 (130) [2]

2240 (350) [2]

2720 (170) [2]

2720 (170) [2]

2720 (170) [2]

Cold Crushing Strength kg/cm² (lb/in²) after firing at 815°C

20 (300) 21 (300) 31 (300) 105 (1500) 525 (7500) 350 (5000) 560 (8000) 560 (8000) 350 (5000)

MOR after firing at 815°C kg/cm² (lb/in²)

20 (300) 7 (100) 12 (180) 25 (350) 70 (1000) 98 (1400) 86 (1200) 105 (1500) 70 (1000)

Permanent Linear Change

-1.5% -0.5% -1.2% -0.2% -0.1% -0.2% -0.1% -0.4% -0.2%

Thermal Conductivity K value in W/m.°C

(Btu-in/ft².F.Hr) at 260°C at 540°C at 815°C

0.21 (1.50) 0.25 (1.70) 0.26 (1.80)

0.18 (1.30) 0.20 (1.40) 0.23 (1.60)

0.35 (2.47) 0.38 (2.63) 0.40 (2.79)

0.40 (2.80) 0.42 (1.95) 0.44 (3.10)

0.24 (1.70) 0.23 (1.65) 0.26 (1.80)

0.95 (6.30) 0.97 (6.90) 1.08 (7.70)

1.56 (10.8) 1.41 (9.8) 1.40 (9.7)

1.61 (11.5) 1.75 (12.5) 1.96 (14.0)

1.61 (11.5) 1.75 (12.5) 1.96 (14.0)

Max. Continuous Use Temperature

1095°C 980°C 1540°C 1200°C 1215°C 1315°C 1700°C 1650°C 1705°C

Notes: [1] Type A Lightweight Insulating Castable (SAMS S/N 32163500) Type B Lightweight Insulating Low Iron Castable (SAMS S/N 32163510) Type C Special Lightweight Insulating Low Iron Castable (SAMS S/N 32163520) Type D Special Medium Weight Insulating Castable (SAMS S/N 32163530) Type E Medium Weight Erosion Resistant Fused Silica Castable (SAMS S/N 32163540) Type F Erosion Resistant Insulating Castable (SAMS S/N 32163550) Type G Hydraulic Setting Erosion Resistant Castable (SAMS S/N 32163560) Type H Chemical Setting Extreme Erosion Resistant Castable (SAMS S/N 32163570) Type I Chemical Setting Extreme Erosion Resistant Plastic (SAMS S/N 32163580) [2] Density with Cast Insulation. [3] Density with Gunnited Installation. [4] Variation of ±10% to the values shown in the table are acceptable except for max. continuous use temperature the values shown are the

minimum.





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Appendix C

Table 3 – Mandatory Refractory Systems

Equipment (Specific Notes)

Operation Condition

Anchors (Material, Sizes

and Types)

Refractory Material (Type, Weight % of Needles

and Application Method) For FCC refractory system, refer to JERES-N-150

Naphtha reformers-reactors wall lining

550°C hydrogen rich atmosphere.

Type 304, 6 mm diameter on a 225 mm square pattern.

Type B (low iron), insulating 100 mm thick, 5% weight Type 304 needles. Shroud supports and vapor stops required to minimize gas bypassing. Gunnited.





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Table 3 – Mandatory Refractory Systems (Cont’d)

Equipment (Specific Notes)

Operation Condition

Anchors (Material, Sizes

and Types)

Refractory Material (Type, Weight % of Needles

and Application Method) Sulfur plants-thermal oxidizer(3) (9) (10)

Temperature <1430°C Type 310 stainless steel V-anchors shall be used to support the castable. Anchor ends shall be located 38 mm from the hot inside surface of the castable. V-anchors shall be supplied preferably bent to shape. They shall be annealed after bending. Anchors shall not be bent after welding in place. Anchors shall be 6 mm thick and spaced a maximum of 300 mm apart.

A single layer of 228 mm (9 in.) thick, 90 percent alumina firebrick (Babcock and Wilcox SR 90, or equivalent) shall be used for the inner layer of the thermal reactor to protect it during short periods of excessive temperature, and to provide adequate mechanical keying strength between bricks. Lightweight castable (Harbison-Walker LW No. 28, or equivalent), 115 mm thick (suitable for temperatures up to 1540°C) shall be used for the outside refractory layer.

Sulfur plants-thermal oxidizer(3) (9) (10)

1540°C oxidizing atmosphere.

Type 310 stainless steel V-anchors shall be used to support the castable. Anchor ends shall be located 38 mm from the hot inside surface of the castable. V-anchors shall be supplied preferably bent to shape. They shall be annealed after bending. Anchors shall not be bent after welding in place. Anchors shall be 6 mm thick, 225 mm square pattern (maximum of 300 mm).

99 percent alumina firebrick for the inner layer Lightweight castable (Harbison-Walker LW No. 28, or equivalent), 115 mm thick (suitable for temperatures up to 1540°C) shall be used for the outside refractory layer.

Sulfur plants-reaction furnace (3) (8) (10) Tubesheet

Anchors shall be 3 mm (1/8 in.) thick UNS R0556 (Haynes 556 or equivalent) material.

Refractory insulation of high-alumina castable material (A. P. Green, Greencast 97, or equivalent), either poured or trowelled between ferrules. Minimum insulation thickness shall be 100 mm (4 in.).

Hydrogen-plants waste heat boilers (shall conform to ASME section I) and transfer lines

840°C hydrogen rich atmosphere

Two component lining: Type 310, 500 mm long, V-type. Shroud lining: Incoloy 800, shrouds.

Two component lining: 1) Type G, erosion resistant (hot

face), 3% weight type 310 needles. Vibration cast or gunnited.

2) Type B, insulating (back up), 5% weight type 304 needles. Vibration cast or gunnited.

Shroud lining:





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Type B (low iron), insulating cast. Waste heat boiler Cold end part 300°C

and above Anchors shall be type AISI304

Refractory lining 50mm minimum thickness

Hydrogen-plants furnaces (3) 1090°C low erosion, oxidizing atmosphere.

Walls: sectionally supported wall anchors or manufacturer’s design. Ceiling: Manufacturter’s design.

Walls: Contractor to propose for Company approval. Ceiling: Type A insulating, 5% weight Type 304 needles, gunnited Floor: High duty firebrick (unmortared) (hot face), Type C (back up). Cast.





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Table 3 – Mandatory Refractory Systems (Cont’d)

Fired heater radiant section or boiler furnace (3) (5) (6) Fired heater convection section

980 - 1310°C oxidizing atmosphere, mechanical and thermal spalling. Up to 980°C.

Side walls and roof: manufacturer’s design Type 310 minimum. Floor: Type 304, 6 mm diameter, V-type on a 225 mm square pattern.

Side walls and roof: Contractor to propose for Company approval. Convection section Type A or D insulating, with optional 5% weight Type 304 needles, gunnited Floor: High duty fireclay brick laid dry (hot face). Type A insulating (back up). Cast. Divider walls super duty and high duty fireclay brick laid with air set mortar and expansion joints. Burner blocks - super duty fireclays or formed air set plastics.

Fired heaters and boilers-stacks (3)

315 - 815°C mild erosion, some mechanical and thermal spalling.

Type 304, 3 mm diameter, V-type.

3 mm thick vapor barrier on shell and breaching. Type A or D insulating thickness with optional 5% weight type 304 needles.

Flare tips (6)(7)(8) 315 - 1090°C mild erosion, some mechanical and thermal spalling.

3 mm diameter, V-type anchors or coiled wire (7)

Both sides, one shot lining, Type G, 5% weight needles, Type 310. Cast or gunnited (if accessible).

General Note: Existing boilers, flare tips, and fired heaters (furnaces) which are refractory-lined with castable type refractories, shall be maintained and repaired using the same refractory systems as specified by the original Equipment Manufacturer. Modifications to original design require Jubail Export Refinery Engineer’s Approval. Specific Notes: (1) Hexsteel with Type H refractory shall be used for new installations, and “S” bars with Type I refractory shall be used for maintenance

repairs. Materials of hexsteel and “S” bars are to be the same material and Type as the equipment. (2) Slide valve bodies are to be lined in accordance with the requirements for FCC standpipes. (3) An asphaltic mastic coating rated to 175°C shall be used for a vapor barrier. (4) Use a refractory material, which is resistant to acidic water. (5) The anchor material specified is for clean fuel (less than 5% sulfur). (6) The anchor materials for flare tips shall be specified in accordance with JERMS-F-3222. (7) Unless otherwise specified by the Equipment Manufacturer, flare tips less than 600 mm nominal diameter shall not be internally lined. (8) The minimum lining thickness shall be 50 mm (9) Two layer refractory system (10) Typical acceptable castable refractory lining material are:

Green Cast 94 Castolast G Plicast 40 Resco RS 17 A Towacast C-18 Restrictions: Fe2O3<6%, CaO<15%, Alkalis<2.5%

jeres n 100 refractory systems

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